Monolithic wall and method of building the same



Aug. 14, 1928.

H. S. ASHENHURST IONOLI'IHIC WALL AND METHOD OF BUILDING THE sun:

Filed Feb. 16. 1925 Patented Aug. 14,1928. I

uNrrEo-ls'r TEs HAROLD s asnmrnunsr, or CHICAGO, ILLINOIS, AssIeNoa, BY MESNE assidu-v PATENT OFFICE.

MEETS, TO INSULEX CORPORATION, OF CHICAGO, ILLI NOIS, A CORPORATION OF DELAWARE.

Application filed February My invention relates to walls for buildings, composed of cellular insulating material such as described inmy prior patent, ReissueNo. 15,952, of November 25, 1924. This material is'formed first in plastic condition by the addition of water to a prepared powder, the same being adapted to expand very materially "and then to set and harden in highly cellular form.

It is one of the objects of my invention to build vertical walls by providing suitable encasing elements for defining the thickness of a wall: and pouring the cellular material while in plastic condition into the form where it expands and sets. It is another object ofimy invention to provide a wall of this type in which there are no parts extending through the wall from one face to the other of a character adapted to conduct heat or sound throu h the wall. To this end, it is one of my 0 jects to provide a construc tion in which the supporting elements of the wall are completely embedded in the body of insulating material.

It is another object of my invention to provide a new and improved arrangement of body and supporting means whereby the upper portion of the wall can be built to advantage at the point adjacent to the ceiling of the room. To this end, it is one of the objects of my invention to provide a construction of such arrangement that the lower portion may be built advantageously in integral form, with the upper portion capable of being completed by the addition of separately formed blocks.

It is another object of my invention to improve walls in sundry details hereinafter pointed out. The preferred means by which I have accomplished my several objects are illustrated in the drawing and are hereinafter specifically described. That which I believe to be. new and desire to cover by this application is set forth in the claims.

In the drawings,- 7 V Fig. 1 is a face view of fragmentary portions of a wall embodying my .invention,

showing the ceiling and the floor of the room MONOLITHIC WALL AND METHOD OF BUILDING THE SAME.

1c, 1925. Serial No. 9,639.

between a floor 11 and a ceiling 12, such studs belng arranged in suitable spaced relation to eachother, About the studs or supports 10,1 have provided a wall body 13 with respect to each other at opposite sidesof the st-udslO and preferably held inv spaced position with respect to said studs so that the face of the wall shall. be continuous past the studs. By employing a form of plastic material such as that disclosed by my prior patent above referred to, I have insured that the body 13 shall be of cellular formation throughout, whereby it may have a high insulating value.

When the body 13 has reached a point adjacent to the ceiling 12 such that it is difficult to pour the plastic material into position between the forms, the integral casting operation is preferably discontinued, the space between the upper edge of the body portion 13 and the ceiling being filled in with blocks 14 formed separately by casting operations conducted preferably near at hand so as to enable the blocks 14 to be is provided, from the standpoint of insulation, the extreme cellularity of the material forming the body 13 and the blocks 14 rendering the material very effective for insulating both heat and sound. By arranging the cellular material so as to extend past bothfaces of the studs 10, the insulation is made much more efiicient as compared with constructions in which the studs extend from oneface of the wall to the other face. At

the same time, the studs .10 are able to reen force and support the cellular material effectively in position so as to secure the desired strength of the wall structure. By using care in the preparation of the forms and'in' the pouring of the wall material, as well as in the arrangement of the blocks 14 at the results'by the use of materials mixed on the job with suflicient water to form a freeflowing paste and poured into place in the form, such materials consisting of ingredients mixed as follows,100 pounds of calcined gypsum, 2 ounces of commercial retarder, pounds of a suitable carbonate such as calcium carbonate, and 8 pounds of aluminum sulphate containing its water of crystallization, all of such ingredients being finely ground and thoroughly mixed in a 7 dry state I also do not wish to be limited with respect to any of the details of the construction, except so far as the same may be specifically claimed, inasmuch as it is evident that changes may well be made from the form shown without departing from the spirit of my invention.

I claim:

1. A wall comprising a body of cellular material of high insulating value and composed mainly of gypsum, of integral construction at its lower portion and built up of separate blocks at its upper portion.

2. A wall comprising in combination a body of cellular material of high insulating value and composed mainly of gypsum, of integral construction at its lower portion and built up of separate blocks at its upper portion, and a plurality of supporting members secured in said body at intervals therealong serving to hold the body rigidly in position with respect thereto.

3. A wall section comprising in combination a plurality of studs extending between a floor and a ceiling and permanently secured in position in spaced relation to each other, and a body of cellular insulating material filling the spaces between the studs and completely surrounding the studs, serving as the body of the wall and being selfsupporting-vertically from the bottom to the topofthe wall section, the major portion at least of the body being ofcontinuous integral formation.

Signed at Chicago, Illinois, this 13th day of February, 1925.

HAROLD S. ASHENHURST. 

